BRAKE PEDAL REMOVAL


  1. DRAIN BRAKE FLUID

    Note

    Wash off brake fluid immediately if it comes in contact with any painted surface.

  2. REMOVE BRAKE MASTER CYLINDER


    1. A003FZAE01
      Text in Illustration
      *A for Manual Transmission
      *B for Automatic Transmission

      Disconnect the warning switch connector and detach the clamp.

    2. Using a union nut wrench, disconnect the 2 brake tubes from the brake master cylinder.

    3. for Manual Transmission:

      Slide the clip disconnect the clutch reservoir tube from the brake master cylinder.

    4. A003D0K

      for 1TR-FE, 2TR-FE:

      Remove the 2 nuts and brake master cylinder.

    5. for 1KD-FTV, 2KD-FTV and 5L-E:


      1. Remove the 2 nuts, and disconnect the bracket.

      2. Remove the brake master cylinder from brake booster.

    6. Remove the O-ring from the brake master cylinder.

      Note


      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.

      • Do not strike or pinch the master cylinder piston, and do not cause any damage the the master cylinder piston by any other means.

      • When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or with its facing downward (the piston faces up ward) to prevent the master cylinder piston from falling out.

      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a piece of cloth, and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.

      • Do not use any other type of grease or fluid.

      • Be careful not to damage the brake tubes.

  3. REMOVE HEADLIGHT ASSEMBLY RH (for RHD with Standard Body)

    Tech Tips

    Remove of the headlight assembly RH is the same as the headlight assembly LH.


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  4. REMOVE HEADLIGHT ASSEMBLY RH (for RHD with Wide Body)

    Tech Tips

    Remove of the headlight assembly RH is the same as the headlight assembly LH.


    1. for Halogen Headlight:

      Click here

    2. for LED Headlight:

      Click here

  5. REMOVE RADIATOR GRILLE (for LHD with Standard Body)

    Click here

  6. REMOVE WINDSHIELD WASHER JAR ASSEMBLY (for LHD with Standard Body)

    Click here

  7. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER

    Click here

  8. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS


    1. Remove the clip and clevis pin and separate the push rod clevis from the brake pedal.

  9. SEPARATE BRAKE TUBE


    1. for Manual transmission:


      1. A003FI0

        Using a union nut wrench, disconnect the clutch tube from the clutch master cylinder.

      2. A003FHO

        Disengage the 3 tubes from the clamp.

    2. for Automatic transmission:

      Disengage the 2 tubes from the clamp.

  10. REMOVE BRAKE BOOSTER ASSEMBLY


    1. A003ETUE01

      Slide the clip, disconnect the vacuum hose.

    2. for 1KD-FTV, 2KD-FTV and 5L-E:

      Disconnect the vacuum warning switch connector and detach the clamp.

    3. A003BMQ

      Remove the 4 nuts and brake booster assembly.

  11. REMOVE BRAKE BOOSTER GASKET

  12. DISCONNECT WIRE HARNESS


    1. A003DLA

      Disconnect the 2 connectors.

  13. REMOVE ACCELERATOR PEDAL ROD ASSEMBLY


    1. A003HHU

      Remove the 2 nuts and accelerator pedal rod assembly.

  14. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY


    1. A003F1B

      Loosening the bolt.

      CAUTION:

      Do not remove the loosened bolt

      Tech Tips

      When loosening the nut, keep the bolt from rotating.

    2. A003FN4

      Remove the 5 bolts, nut and the brake pedal support assembly.